I did some research but I have a question, my '89 clip ons have the threads inside the bars, so other than the stock bar ends what are my options? Can I drill out the bar so I can just buy the expanding bar ends? The vibration is getting old.

If it was me I would just go buy some 7/8" Aluminum or Steel Stock and make your own bars and keep the originals as backup.

You just have to make a crecesent shape cutout and drill the hole for the controls

are you sure you can't use the expandables with threads? dunno... just a thought.

Quote from: coll0412 on June 08, 2007, 05:38:33 PM
If it was me I would just go buy some 7/8" Aluminum or Steel Stock and make your own bars and keep the originals as backup.

You just have to make a crecesent shape cutout and drill the hole for the controls

+1

that's what i did.

Quote from: WREX on June 08, 2007, 08:34:04 PM

Quote from: coll0412 on June 08, 2007, 05:38:33 PM
If it was me I would just go buy some 7/8" Aluminum or Steel Stock and make your own bars and keep the originals as backup.

You just have to make a crecesent shape cutout and drill the hole for the controls

+1

that's what i did.

What is the crecesent shape cutout for? I know where the holes for the controls go, but what is the crecesent cut out and where is it?

if you pull out the stock ones, you'll see where the crecent is on the bars. 

there are 2 bolts for each bar that secure them in.  one of the bolts doesn't interfere with the bar sliding in and out of the clamp and is more a pressure fit.  the other is set in a bit that you can't have the bolt threaded before sliding in.  you need to slide the bar in first, line up the crecent and then thread the bolt in.  once the bolt is in (even when loose), you can't twist the bar or pull it out of the clamp.

its pretty straight forward to cut out.  i just used a dremel until the bolt fit.

you can also go thicker walled tube (i used 1/8 thick) but you'd need thinner insert barends (the route i went) or machine the bars to fit regular sized barends, if you still want to have them. 

Decided to ressurect my old thread instead of starting a new one.

Anyway I went to home depot to buy some 7/8" steel tubing yesterday. I took one of my clip on bars in for reference. An employee pointed me to an aisle with steel tubing but they didn't have any 7/8", only 1/2, 3/4, and 1 in. I held my bar up to the 1/2" and they looked pretty darn close. Only $2 what the heck i'll try it. Put them on today and they are just a tad smaller in diameter than my stock bars. The perch for the choke/lights/turn signals, cant tighten enough, it still spins when I move the choke.

So I have two options, find some way to get that to stop spinning. Or find some 7/8" tubing (which I would prefer) why didn't home depot have any? Where can I find some? Thanks guys.

Quote from: bucks1605 on August 05, 2007, 12:19:00 PM
Decided to ressurect my old thread instead of starting a new one.

Anyway I went to home depot to buy some 7/8" steel tubing yesterday. I took one of my clip on bars in for reference. An employee pointed me to an aisle with steel tubing but they didn't have any 7/8", only 1/2, 3/4, and 1 in. I held my bar up to the 1/2" and they looked pretty darn close. Only $2 what the heck i'll try it. Put them on today and they are just a tad smaller in diameter than my stock bars. The perch for the choke/lights/turn signals, cant tighten enough, it still spins when I move the choke.

So I have two options, find some way to get that to stop spinning. Or find some 7/8" tubing (which I would prefer) why didn't home depot have any? Where can I find some? Thanks guys.

Go buy a rim strip for a wide mountain bike wheel and some trim adhesive from an auto parts store.Cut it so the rubber wraps around the bar and the ends touch.Glue them on and put your controls on top.With the grips,spray hairspray on the bar and in the grip,install or use grip glue.

Oh,          my.

Quote from: ohgood on August 05, 2007, 02:58:43 PM
Oh,          my.

What!I did it on dirt bikes and thier bars take a whole lot more abuse that road bike bars.

Quote from: ben2go on August 05, 2007, 05:32:31 PM
What!I did it on dirt bikes and thier bars take a whole lot more abuse that road bike bars.

I'm not questioning that method.

Does anyone know anything simpler?

Quote from: bucks1605 on August 06, 2007, 10:45:18 AM

Quote from: ben2go on August 05, 2007, 05:32:31 PM
What!I did it on dirt bikes and thier bars take a whole lot more abuse that road bike bars.

I'm not questioning that method.

Does anyone know anything simpler?

Buy new bars. 

i bought replacement bars for my 89 clip ons for 20 bucks on e-bay, all the right size and predrilled.  so no hassle at all

Quote from: ben2go on August 06, 2007, 10:52:22 AM

Quote from: bucks1605 on August 06, 2007, 10:45:18 AM

Quote from: ben2go on August 05, 2007, 05:32:31 PM
What!I did it on dirt bikes and thier bars take a whole lot more abuse that road bike bars.

I'm not questioning that method.

Does anyone know anything simpler?

Buy new bars. 

That's what I tried to do, but home depot didn't have 7/8".

Well shop somewhere else then.

ok thanks for all the help guys

I don't know how things work over there, but where ever you buy steel stock, try there for some 7/8 tubing.

yeah, you need to go to a metal supply place, not home depot.  See if they have any cut offs, otherwise you might have to buy a half length (10'.)

Quote from: bucks1605 on August 06, 2007, 01:53:56 PM

Quote from: ben2go on August 06, 2007, 10:52:22 AM

Quote from: bucks1605 on August 06, 2007, 10:45:18 AM

Quote from: ben2go on August 05, 2007, 05:32:31 PM
What!I did it on dirt bikes and thier bars take a whole lot more abuse that road bike bars.

I'm not questioning that method.

Does anyone know anything simpler?

Buy new bars. 


You know I'm talking about buying real motorcycle bars,not BS from Home De pot. 

That's what I tried to do, but home depot didn't have 7/8".